Apparatus for treatment of crankcase emissions materials in a positive crankcase ventilation system

ABSTRACT

An apparatus for the treatment of gases in a positive crankcase ventilation (PCV) system, in an internal combustion engine, is provided with a housing defining a gas treatment chamber. At least one gas filtering medium is disposed in the treatment chamber, and the gases from the engine crankcase are passed through the gas filtering medium in the treatment chamber, before the gases are routed into the air intake portion of the engine. In addition, the gases, after passage through the gas filtering medium, are passed through an ionization device.

This application claims priority under 35 U.S.C. §120 of the filing dateof Nov. 13, 1997 of U.S. patent application Ser. No. 08/968,594, nowpending.

BACKGROUND OF THE INVENTION

1. The Field of the Invention

The present invention relates in general to pollution control devicesand efficiency devices in internal combustion engines. In particular,the present invention is directed to an apparatus to be installed in thepositive crankcase ventilation (PCV) system of an internal combustionengine.

2. Background of the Invention

In internal combustion engines of the type employing reciprocatingpistons which drive a crankshaft to deliver torsional power, forexample, a common automobile engine, it is well known that a portion ofthe combustion gases which are formed in the combustion chambers of thecylinders are driven by pressure, as well as the partial suction behindthe pistons, past the pistons toward and into the crankcase area of theengine. This phenomenon is known as “blow-by”.

Crankcase ventilation gases will contain various amounts of unburnedgasoline vapor, raw gasoline, motor oil and motor oil fumes, in additionto combustion gases. These materials may be present in any variety ofmolecular weights ranging from the lightest fractions of the gasoline tothe heaviest fractions of the lubricating oil, including additives.Heavy hydrocarbon sludge may also be present. Combustion byproducts suchas carbon dioxide, carbon monoxide, nitrous oxide and water will also bepresent. Dirt and particulate matter that accumulates in the oil pan ofthe engine may also be present in the crankcase vent gases in the formof environmental grit and/or ash and carbon from decomposed oil andfuel.

The gases, vapors, liquids and particulate matter being returned to theintake manifold of the engine via a standard PCV system will containcontinuously varying amounts of amorphous organic and inorganiccompounds. Oils mixed with gasoline will have various degrees offlammability. The more gasoline, the lower the flash point. As more oilis present, the flash point temperature will increase. Oily vapor andoily gasoline entering an engine combustion chamber via the PCV systemmay retard ignition and reduce efficiency of the engine. Particulate andsludge contaminants will further retard combustion, increasing pollutionfrom the engine, in particular carbon monoxide and hydrocarbonemissions. Fuel economy may also be adversely affected. Particulatematter returned to the engine intake manifold presents additionalpotential problems which may include: damage to cylinder walls andpiston rings that will reduce engine performance and life, increasedfuel and moisture passage into the crankcase. In addition, the variousmaterials being ejected from the crankcase through the PCV valve isnonhomogeneous over time, and may lead to the sticking and ultimatepremature failure of the PCV valve, requiring replacement more oftenthan would otherwise be necessary.

Prior art devices intended to provide separation of oily and/orparticulate materials from internal combustion engine gases, such ascrankcase emissions materials, are disclosed in such references as Maio,U.S. Pat. No. 1,772,011; Roper, U.S. Pat. No. 3,072,112; Walker, U.S.Pat. No. 4,269,607; Goldberg, U.S. Pat. No. 4,409,950; Oetting, U.S.Pat. No. 4,834,028; and United Kingdom, 1,572,664. However, such priorart apparatus tend to suffer from a common drawback that such apparatusare typically not configured for practical use within the enginecompartment of a vehicle, and are particularly illsuited for use inmodern vehicles, in which engine compartment space is at a premium.

Devices are also known which expose internal combustion engine fluids,either prior to or after combustion, to electrostatic fields. Suchdevices are disclosed in such references as Edwards, U.S. Pat. No.3,406,669; Bolasny, U.S. Pat. No. 3,878,469; Bolasny, U.S. Pat. No.4,069,665; McMahon, U.S. Pat. No. 4,073,273; Nelson et al., U.S. Pat.No. 4,355,969; and Dalupan, U.S. Pat. No. 5,243,946.

Dalupan, U.S. Pat. No. 5,243,950, discloses an apparatus for thetreatment of gases in a positive crankcase ventilation system, in whichgases, emanating from the crankcase are passed through a chamber,through which a filtering medium is circulated. The gases areconstrained to pass through the filtering medium, which is water or awater/glycol based mixture. After passage through the filtering medium,the gases are then generally conducted past ion emitting electrodesextending into a portion of the chamber. The chamber and ionizer unitare all configured as a single unit. Although the apparatus of theDalupan '950 reference may affect removal of some oily and/orparticulate materials from crankcase emissions materials, and may impartsome ionization effect to the “cleaned” gases, further enhancement ofthe filtering and ionization effects is possible and desirable. Inaddition, the configuration and bulk of the apparatus of the Dalupan'950 reference is not conducive to installation in modern vehicle enginecompartments.

Accordingly, it would be desirable to provide an improved apparatus forthe treatment of internal combustion engine gases, in particularcrankcase emissions materials.

It would further be desirable to provide an improved apparatus for thetreatment of internal combustion engine gases, in particular, crankcaseemissions materials, which employs a liquid filtration system, which hasimproved resistance to spillage and resistance to siphoning of a liquidfiltering medium into the engine.

These and other objects of the invention will become apparent in lightof the present specification, including claims, and drawings.

SUMMARY OF THE INVENTION

The present invention comprises, in part, a system for the treatment ofcrankcase emissions materials, in a positive crankcase ventilationsystem of an internal combustion engine, in which the crankcaseemissions materials, containing at least one of partially and completelyunburned hydrocarbon materials, oil, particulate materials and gaseouscombustion byproducts, and are drawn from the crankcase of the engineand directed to an air intake portion of the engine for recirculationthrough and further combustion in the engine.

The system for treatment of crankcase emissions materials in a positivecrankcase ventilation system comprises a filtering apparatus, operablyconfigured to receive therethrough crankcase emissions materialsconducted substantially directly from the crankcase of an internalcombustion engine, for substantially separating removing said at leastone of partially and completely unburned hydrocarbon materials, oil,particulate materials and gaseous combustion byproducts from crankcaseemissions materials. A positive crankcase ventilation valve is operablypositionable downstream from the filtering apparatus, for regulating thepressure of crankcase emissions materials passing through the filteringapparatus. An electronic apparatus is operably positionable downstreamfrom the positive crankcase ventilation valve, for imparting anelectrostatic charge to the filtered crankcase emissions materials,prior to delivery of the filtered crankcase emissions materials to theair intake portion of an internal combustion engine.

Preferably, the filtering apparatus comprises a housing, having an inletand an outlet, with portions of the housing defining a first treatmentchamber. The inlet of the housing is connectable, at least indirectly,to a positive crankcase ventilation outlet of an internal combustionengine. The outlet of the housing is connectable, at least indirectly,to a positive crankcase ventilation vacuum port of an internalcombustion engine. Liquid filtering medium is disposed in the firsttreatment chamber for substantially separating oil and particulatematerial from the crankcase emissions materials. At least one flowdirecting member is operably configured for constraining introduction ofthe crankcase emissions materials, from the crankcase, into the liquidfiltering medium. At least one porous flow restriction member isoperably disposed within the housing, for substantially precludingpassage of non-gaseous material from the housing, once the crankcaseemissions materials have been introduced into the liquid filteringmedium.

Preferably, the housing comprises a lid and a substantially hollowreservoir, operably configured for receiving the liquid filteringmedium.

In an embodiment, in which the inlet is disposed in the lid, the flowdirecting member comprises a tubular member, substantially aligned withthe inlet and extending into the substantially hollow reservoir. The atleast one porous flow restriction member comprises at least one flowrestriction member, operably associated with the lid, for substantiallyprecluding passage of non-gaseous material, downstream from the housing,toward the vacuum port of the internal combustion engine, upon exertionof a suction, of an amount in excess of a predetermined amount, upon thehousing from the vacuum port.

Preferably, the lid further comprises a cover member, inlet and outletopenings disposed in the cover member, and an outlet boss, operablyaligned with the outlet opening. The outlet boss being operablyconfigured for receipt therein at least one porous flow restrictionmember. A baffle plate member is substantially sealingly affixablewithin the cover member, for operably defining therebetween a secondtreatment chamber, which is substantially segregated from the firsttreatment chamber when the lid is positioned on the reservoir. An inletpassage is disposed in the baffle plate member, for enabling passage ofcrankcase emissions materials from the inlet opening into the firsttreatment chamber. The baffle plate inlet passage is substantiallyaligned with the inlet opening in the cover member. An intermediatepassage is disposed in the baffle plate member, for enabling passage oftreated crankcase emissions materials from the first treatment chamberand out of the housing through the outlet opening in the cover member.The intermediate passage is disposed in a substantially nonalignedrelationship with the outlet opening of the cover member.

Means may be operably disposed in the first treatment chamber, forfacilitating the chemical alteration of at least a portion of thecrankcase emissions materials. The means for facilitating chemicalalteration of at least a portion of the crankcase emissions materialscomprise means for establishing a galvanic cell in the reservoir. Themeans for establishing a galvanic cell in the reservoir may consist ofat least one of the following: members made of dissimilar metals in thegalvanic series.

Preferably, the electronic apparatus comprises an electronic ionizerapparatus for imparting a charged particle field to treated crankcaseemissions materials exiting from the housing having liquid filteringmedium therein, the electronic ionizer apparatus being operablypositioned downstream from the housing having liquid filtering mediumtherein.

The electronic ionizer apparatus preferably comprises a housing, havingan inlet and an outlet. Portions of the housing define an electronictreatment chamber, in which the inlet of the ionizer is operablyconnectable, at least indirectly, to a positive crankcase ventilationoutlet of an internal combustion engine. The outlet of the housing isoperably connectable, at least indirectly, to a positive crankcaseventilation vacuum port of an internal combustion engine. Electroniccircuitry, operably associated with the housing and including at leastone emitter pin operably emanating into the electronic treatmentchamber, produces ionic emanations for producing a charged particlefield within the crankcase emissions materials. The portions of thehousing defining the electronic treatment chamber include one or morewall members configured for producing a swirling motion to the crankcaseemissions materials entering the electronic treatment chamber from theinlet of the housing, around the at least one emitter pin.

Preferably, the liquid filtering medium consists of a mixture of waterand at least one of the following: an antifreezing agent, an alcohol,hydrogen peroxide.

The present invention also comprises, in part, in an alternativeembodiment, a system for the treatment of crankcase emissions materials,in a positive crankcase ventilation system of an internal combustionengine, in which the crankcase emissions materials, containing partiallyand completely unburned hydrocarbon materials, oil, particulatematerials and/or gaseous combustion byproducts, are drawn from thecrankcase of the engine and directed to an air intake portion of theengine for recirculation through and further combustion in the engine.

The system, in this alternative embodiment, comprises a filteringapparatus, operably configured for containing a liquid filtering medium,and to receive therethrough crankcase emissions materials from theinternal combustion engine, for substantially separating removing oilymaterials and/or particulate materials from the crankcase emissionsmaterials, including a housing operably configured for containing aliquid filtering medium. An inlet receives crankcase emissionsmaterials. Means are provided for directing crankcase emissionsmaterials from the inlet into a liquid filtering medium contained withinthe housing, toward separating oily and/or particulate materials fromgaseous materials in the crankcase emissions materials. An outletpermits escape of filtered crankcase emissions materials from thehousing. Means are provided for substantially precluding the escape ofliquid filtering medium from the housing. An electronic apparatus isoperably positioned downstream from the filtering apparatus forelectronically treating the filtered crankcase emissions materials.

The means for substantially precluding the escape of liquid filteringmedium from the housing comprise at least one porous barrier member,operably associated with at least one of the inlet and outlet.

In another alternative embodiment of the invention, the system comprisesa filtering apparatus, operably configured to receive therethroughcrankcase emissions materials from the internal combustion engine, forsubstantially separating removing oily materials and/or particulatematerials from the crankcase emissions materials. An electronic ionizerapparatus, operably positionable downstream from the filteringapparatus, imparts an electrostatic charge to the filtered crankcaseemissions materials, prior to delivery of the filtered crankcaseemissions materials to the air intake portion of an internal combustionengine. The electronic ionizer apparatus includes a housing, having aninlet and an outlet. Portions of the housing define an electronictreatment chamber. The inlet of the housing is connectable, at leastindirectly, to a positive crankcase ventilation outlet of an internalcombustion engine. The outlet of the housing is operably connectable, atleast indirectly, to a positive crankcase ventilation vacuum port of aninternal combustion engine. Electronic circuitry is operably associatedwith the housing and includes at least one emitter pin operablyemanating into the electronic treatment chamber, for producing ionicemanations for producing a charged particle field within the crankcaseemissions materials.

The portions of the housing defining the electronic treatment chamberinclude one or more wall members configured for producing a swirlingmotion to the crankcase emissions materials entering the electronictreatment chamber from the inlet of the housing, around the at least oneemitter pin.

In addition, the invention also comprises, in part, an apparatus for thetreatment of crankcase emissions materials, in a positive crankcaseventilation system of an internal combustion engine, in which thecrankcase emissions materials, containing partially and completelyunburned hydrocarbon materials, oil, particulate materials and/orgaseous combustion byproducts, are drawn from the crankcase of theengine and directed to an air intake portion of the engine forrecirculation through and further combustion in the engine.

A housing has an inlet and an outlet. Portions of the housing define afirst treatment chamber. As previously stated, the inlet of the housingmay be operably connectable, at least indirectly, to a positivecrankcase ventilation outlet of an internal combustion engine. Likewise,the outlet of the housing may be operably connectable, at leastindirectly, to a positive crankcase ventilation vacuum port of aninternal combustion engine. Liquid filtering medium may be disposed inthe first treatment chamber, for substantially separating oil andparticulate material from the crankcase emissions materials. At leastone flow directing member may be operably configured for constrainingintroduction of the crankcase emissions materials, from the crankcase,into the liquid filtering medium.

At least one porous flow restriction member, as previously mentioned,may be operably disposed within the housing, for substantiallyprecluding passage of non-gaseous material from the housing, once thecrankcase emissions materials have been introduced into the liquidfiltering medium. The housing includes a lid; and a substantially hollowreservoir, operably configured for receiving the liquid filteringmedium. The inlet is disposed in the lid. The flow-directing memberpreferably may be a tubular member, substantially aligned with the inletand extending into the substantially hollow reservoir. The at least oneporous flow restriction member preferably is a flow restriction member,operably associated with the lid, for substantially precluding passageof non-gaseous material, downstream from the housing, toward the vacuumport of the internal combustion engine, upon exertion of a suction, ofan amount in excess of a predetermined amount, upon the housing from thevacuum port. Alternatively, the at least one porous flow restrictionmember may comprise a flow restriction member, operably associated withthe lid, for substantially precluding passage of non-gaseous material,upstream from the housing, toward the crankcase upon exertion of asuction from the crankcase upon the housing.

The lid preferably includes a cover member with an inlet opening and anoutlet opening, and an outlet boss, operably aligned with the outletopening. The outlet boss is operably configured for receipt therein atleast one porous flow restriction member. The lid also includes, asmentioned, a baffle plate member, with an inlet passage, and anintermediate passage disposed in the baffle plate member, for enablingpassage of treated crankcase emissions materials from the firsttreatment chamber and out of the housing through the outlet opening inthe cover member, the intermediate passage being disposed in asubstantially nonaligned relationship with the outlet opening of thecover member.

The means, operably disposed in the first treatment chamber, forfacilitating the chemical alteration of at least a portion of thecrankcase emissions materials, comprise means for establishing agalvanic cell in the reservoir. The means for establishing a galvaniccell in the reservoir may consist of members made of dissimilar metalsin the galvanic series.

In the present invention, the liquid filtering medium preferablyconsists of a mixture of water and at least one of the following: anantifreezing agent, an alcohol, hydrogen peroxide.

The present invention also comprises, in part, an electronic ionizerapparatus for the treatment of crankcase emissions materials, in apositive crankcase ventilation system of an internal combustion engine,in which the crankcase emissions materials, containing partially andcompletely unburned hydrocarbon materials, oil, particulate materialsand/or gaseous combustion byproducts, and are drawn from the crankcaseof the engine and directed to an air intake portion of the engine forrecirculation through and further combustion in the engine.

As previously mentioned, the electronic ionizer apparatus for treatmentof crankcase emissions materials in a positive crankcase ventilationsystem may comprise a housing, having an inlet and an outlet. Portionsof the housing define an electronic treatment chamber. The inlet of thehousing preferably is operably connectable, at least indirectly, to apositive crankcase ventilation outlet of an internal combustion engine.The outlet of the housing likewise is preferably operably connectable,at least indirectly, to a positive crankcase ventilation vacuum port ofan internal combustion engine. The electronic ionizer apparatus alsoincludes electronic circuitry, operably associated with the housing andincluding at least one emitter pin operably emanating into theelectronic treatment chamber, for producing ionic emanations forproducing a charged particle field within the crankcase emissionsmaterials. The portions of the housing which the electronic treatmentchamber, include one or more wall members configured for producing aswirling motion to the crankcase emissions materials entering theelectronic treatment chamber from the inlet of the housing, around theat least one emitter pin.

The present invention also comprises, in part, an apparatus for mountingcomponents in an engine compartment of an internal combustionengine-powered vehicle. The mounting apparatus comprises a first bracketmember, having a longitudinal axis and one or more attachment aperturestherewithin, operably arranged on the first bracket member, in a row,substantially parallel to the longitudinal axis, the first bracketmember being operably configured for affixation to an accessory for aninternal combustion engine for a vehicle. A second bracket member has asubstantially L-shaped configuration. First and second attachmentregions are operably configured for attachment thereat, to the firstbracket member. The first and second attachment regions are preferablyoperably arranged so that the first bracket member may be oriented in arange of positions, when attached to the first attachment region, whichis substantially perpendicular to range of positions in which the firstbracket member may be oriented, when attached to the second attachmentregion. The second bracket member further has a third attachment region,operably configured for attachment of the second bracket member, to astructure in an engine compartment of a vehicle.

An alternative embodiment of the invention comprises a system for thetreatment of crankcase emissions materials, in a positive crankcaseventilation system of an internal combustion engine, in which thecrankcase emissions materials, containing at least one of partially andcompletely unburned hydrocarbon materials, oil, particulate materialsand gaseous combustion byproducts, are drawn from the crankcase of theengine and directed to an air intake portion of the engine forrecirculation through and further combustion in the engine.

The system comprises a filtering apparatus, for containing a liquidfilter medium, the filtering apparatus being operably configured toreceive therethrough crankcase emissions materials conductedsubstantially directly from the crankcase of an internal combustionengine, for substantially separating said at least one of said partiallyand completely unburned hydrocarbon materials, oil, particulatematerials and gaseous combustion byproducts from crankcase emissionsmaterials.

A positive crankcase ventilation valve is operably positioned downstreamfrom the filtering apparatus, for regulating the pressure of crankcaseemissions materials passing through the filtering apparatus;

An electronic apparatus is operably positioned downstream from thepositive crankcase ventilation valve, for imparting an electrostaticcharge to the filtered crankcase emissions materials, prior to deliveryof the filtered crankcase emissions materials to the air intake portionof an internal combustion engine.

The filtering apparatus further comprises a housing, having an inlet andan outlet. The inlet of the housing is operably connected, at leastindirectly, to a positive crankcase ventilation outlet of an internalcombustion engine. The outlet of the filter medium reservoir is operablyconnected, at least indirectly, to a positive crankcase ventilationvacuum port of an internal combustion engine.

At least one baffle member is operably disposed within the housing, andconfigured for constraining introduction of the crankcase emissionsmaterials, from the crankcase, into at least one treatment chamberdefined by the housing and the at least one baffle member.

The housing preferably comprises, in this alternative embodiment, asubstantially hollow reservoir base operably configured for receivingand containing a liquid filter medium; and a reservoir top, including aninner treatment chamber, and a surrounding outer treatment chamber. Thereservoir base is preferably an open-topped treatment chamber, definedby a first tubular side wall having an upper rim, and a bottom wall. Theinner treatment chamber of the reservoir top is an open-bottomedtreatment chamber, defined by a second tubular side wall having a lowerrim. The outer treatment chamber is defined by a third tubular side wallsurrounding at least a portion of the second tubular side wall, the wallof the outer treatment chamber having a lower rim.

The inlet is disposed in the reservoir top, in fluid communication withthe outer treatment chamber thereof, and the outlet is also disposed inthe reservoir top, in fluid communication with the inner treatmentchamber thereof. Preferably, the at least one baffle member comprises anopen-topped tubular member, operably configured, upon positioning withinthe housing, for defining an inner treatment chamber of the reservoirbase, that is in fluid communication with the inner treatment chamber ofthe reservoir top, and an outer treatment chamber, disposed between atubular side wall of the tubular member and the first tubular side wallof the reservoir base; the outer treatment chamber being in fluidcommunication with the outer treatment chamber of the reservoir top. Atleast one aperture extends through the tubular side wall of the tubularmember. The tubular member is further operably configured forcooperation with the reservoir top, so that upon assembly of the housingand at least one baffle member, direct fluid communication between theouter treatment chamber of the reservoir top and the inner treatmentchamber of the reservoir top are substantially precluded, so that fluidpassing through the housing is constrained to pass, in succession, intothe inlet, through the outer treatment chamber of the reservoir top, tothe outer treatment chamber of the reservoir base, then to the innertreatment chamber of the reservoir base, then to the inner treatmentchamber of the reservoir top and through the outlet, thus passingthrough liquid filter medium that may be disposed within the reservoirbase.

Preferably, the tubular member further comprises a first tubularportion, having an upper rim region and operably configured to bereceived within the reservoir base, and having a width substantiallyequal to the width of the lower rim of the wall of the inner treatmentchamber of the reservoir top. At least one abutment surface is disposedproximate the upper rim region of the first tubular portion, forengaging the lower rim of the wall of the inner treatment chamber of thereservoir top, when the tubular member is placed in the reservoir baseand the reservoir base and reservoir top are assembled, so that thereservoir top forces a lower rim of the first tubular portion of thetubular member against the bottom wall of the reservoir base, to createsubstantially fluid tight seals between the lower rim of the innertreatment chamber of the reservoir top and the at least one abutmentsurface, and between the lower rim of the first tubular portion of thetubular member and the bottom wall of the reservoir base.

The at least one aperture in the tubular member is disposed proximatethe upper rim region of the first tubular portion. Alternatively, the atleast one aperture in the tubular member is disposed proximate the lowerrim of the first tubular portion. As a still further alternative, the atleast one aperture in the tubular member comprises at least twoapertures in the first tubular portion, at least a first of the at leasttwo apertures being disposed proximate the upper rim region of the firsttubular portion, and at least a second of the at least two aperturesbeing disposed proximate the lower rim of the first tubular portion.

An alternative embodiment of the invention further comprises means forinhibiting suction of liquid filter medium into the intake system of aninternal combustion engine to which the system is connected. The upperrim region of the first tubular portion of the tubular member defines apredetermined height corresponding to a maximum amount of liquid filtermedium to be placed in the housing. The means for inhibiting suction offilter medium further comprises a second tubular portion of the tubularmember, having a diameter predominantly less than the diameter of theinner treatment chamber of the reservoir top. The second tubular portionof the tubular member emanates from and extending above the firsttubular portion of the tubular member, to an elevation higher than theoutlet of the inner treatment chamber of the reservoir top, when thehousing and at least one baffle member are assembled, so that thehousing may be tipped up to a predetermined angle, without having filtermedium reach the outlet of the housing.

Means are provided for returning liquid filter medium, that may becarried out of the inner treatment chamber of the reservoir base andsubsequently condense in the inner treatment chamber of the reservoirtop, to the inner treatment chamber of the reservoir base. The means forreturning filter medium preferably comprises a top wall of the innertreatment chamber of the reservoir top, contoured to have a low pointdisposed above the open top of the tubular member, so that filter mediumthat may condense on an inner surface of the top wall of the innertreatment chamber will be prompted to collect and drip off from the lowpoint, back into the inner treatment chamber of the reservoir base. Themeans for returning filter medium may alternatively comprise an aperturein the second tubular portion of the tubular member, for permittingcondensed liquid filtering material that may become trapped between thesecond tubular portion of the tubular member and the wall of the innertreatment chamber of the reservoir top, to flow back into the innertreatment chamber of the reservoir base.

The system may further comprise means, operably disposed in thereservoir base, for facilitating the chemical alteration of at least aportion of the crankcase emissions materials. The means for facilitatingchemical alteration of at least a portion of the crankcase emissionsmaterials may comprise means for establishing a galvanic cell in thereservoir base.

The means for establishing a galvanic cell in the reservoir base maycomprise at least one material from the group consisting of members madeof dissimilar metals in the galvanic series.

The electronic apparatus may comprise an electronic ionizer apparatusfor imparting a charged particle field to treated crankcase emissionsmaterials exiting from the housing for a liquid filter medium therein,the electronic ionizer apparatus being operably positioned downstreamfrom the housing for a liquid filter medium therein. The electronicionizer apparatus may further comprise a housing, having an inlet and anoutlet, portions of the housing defining an electronic treatmentchamber. The inlet of the housing may be operably connectable, at leastindirectly, to a positive crankcase ventilation outlet of an internalcombustion engine. The outlet of the housing may be operablyconnectable, at least indirectly, to a positive crankcase ventilationvacuum port of an internal combustion engine. Electronic circuitry, maybe operably associated with the housing and including at least oneemitter pin operably emanating into the electronic treatment chamber,for producing ionic emanations for producing a charged particle fieldwithin the crankcase emissions materials. The portions of the housingdefining the electronic treatment chamber include one or more wallmembers configured for producing a swirling motion to the crankcaseemissions materials entering the electronic treatment chamber from theinlet of the housing, around the at least one emitter pin.

Preferably, in an alternative embodiment of the invention, thecross-sections of each of the first tubular side wall, the secondtubular side wall, the third tubular side wall and the tubular side wallof the tubular member have a common configuration selected from thegroup of shapes consisting of: cylindrical, rectangular, triangular.

The housing may comprise a substantially hollow reservoir operablyconfigured for receiving and containing a liquid filter medium. The atleast one baffle member may comprise an open-topped tubular member,disposed within the housing, and defining a generally cylindrical innertreatment chamber and a generally annular outer treatment chamber.

A fluid separator member may be operably disposed between the housingand the at least one baffle member, for partitioning the generallyannular outer member into a first annular outer member in direct fluidcommunication with the inlet to the housing, and a second annular outermember in direct fluid communication with the outlet from the housing.

At least one circumferentially extending baffle wall may emanateupwardly from the at least one baffle member toward a top wall of thehousing. At least one circumferentially extending baffle wall mayemanate downwardly from a top wall of the housing toward the at leastone baffle member.

In another alternative embodiment of the invention, the inventioncomprises an apparatus for the treatment of crankcase emissionsmaterials, in a positive crankcase ventilation system of an internalcombustion engine, in which the crankcase emissions materials,containing at least one of partially and completely unburned hydrocarbonmaterials, oil, particulate materials and gaseous combustion byproducts,are drawn from the crankcase of the engine and directed to an air intakeportion of the engine for recirculation through and further combustionin the engine.

The apparatus for treatment of crankcase emissions materials in apositive crankcase ventilation system may comprise a filteringapparatus, for containing a liquid filter medium, the filteringapparatus being operably configured to receive therethrough crankcaseemissions materials conducted substantially directly from the crankcaseof an internal combustion engine, for substantially separating removingsaid at least one of said partially and completely unburned hydrocarbonmaterials, oil, particulate materials and gaseous combustion byproductsfrom crankcase emissions materials.

The filtering apparatus may include a housing, having an inlet and anoutlet. The inlet of the housing may be operably connected, at leastindirectly, to a positive crankcase ventilation outlet of an internalcombustion engine. The outlet of the filter medium reservoir may beoperably connected, at least indirectly, to a positive crankcaseventilation vacuum port of an internal combustion engine. At least onebaffle member may be operably disposed within the housing, andconfigured for constraining introduction of the crankcase emissionsmaterials, from the crankcase, into at least one treatment chamberdefined by the at least one baffle member and the housing.

The housing may further comprise a substantially hollow reservoir baseoperably configured for receiving and containing a liquid filter medium;and a reservoir top, including an inner treatment chamber, and asurrounding outer treatment chamber.

The reservoir base may be an open-topped treatment chamber, defined by afirst tubular side wall having an upper rim, and a bottom wall. Theinner treatment chamber of the reservoir top may be an open-bottomedtreatment chamber, defined by a second tubular side wall having a lowerrim; and the outer treatment chamber may be defined by a third tubularside wall surrounding at least a portion of the substantially tubularwall of the inner treatment chamber, the wall of the outer treatmentchamber having a lower rim.

The inlet may be disposed in the reservoir top, in fluid communicationwith the outer treatment chamber thereof, and the outlet is alsodisposed in the reservoir top, in fluid communication with the innertreatment chamber thereof. The at least one baffle member may comprisean open-topped tubular member, operably configured, upon positioningwithin the housing, for defining an inner treatment chamber of thereservoir base, that is in fluid communication with the inner treatmentchamber of the reservoir top, and an outer treatment chamber, disposedbetween a tubular side wall of the tubular member and the first tubularside wall of the reservoir base; the outer treatment chamber being influid communication with the outer treatment chamber of the reservoirtop. At least one aperture may extend through the tubular side wall ofthe tubular member. The tubular member may be further operablyconfigured for cooperation with the reservoir top, so that upon assemblyof the housing and at least one baffle member, direct fluidcommunication between the outer treatment chamber of the reservoir topand the inner treatment chamber of the reservoir top are substantiallyprecluded, so that fluid passing through the housing is constrained topass, in succession, into the inlet, through the outer treatment chamberof the reservoir top, to the outer treatment chamber of the reservoirbase, then to the inner treatment chamber of the reservoir base, then tothe inner treatment chamber of the reservoir top and through the outlet,thus passing through liquid filter medium that may be disposed withinthe reservoir base.

The tubular member may further comprise a first tubular portion, havingan upper rim region and operably configured to be received within thereservoir base, and having a width substantially equal to the width ofthe lower rim of the wall of the inner treatment chamber of thereservoir top. At least one abutment surface, disposed proximate anupper rim region of the first tubular portion, for engaging the lowerrim of the wall of the inner treatment chamber of the reservoir top,when the tubular member is placed in the reservoir base and thereservoir base and reservoir top are assembled, so that the reservoirtop forces a lower rim of the first tubular portion of the tubularmember against the bottom wall of the reservoir base, to createsubstantially fluid tight seals between the lower rim of the innertreatment chamber of the reservoir top and the at least one abutmentsurface, and between the lower rim of the first tubular portion of thetubular member and the bottom wall of the reservoir base.

The at least one aperture in the tubular member may be disposedproximate the upper rim region of the first tubular portion. The atleast one aperture in the tubular member may be disposed proximate thelower rim of the first tubular portion. The at least one aperture in thetubular member may comprise at least two apertures in the first tubularportion, at least a first of the at least two apertures being disposedproximate the upper rim region of the first tubular portion, and atleast a second of the at least two apertures being disposed proximatethe lower rim of the first tubular region.

Means may be provided for inhibiting suction of liquid filter mediuminto the intake system of an internal combustion engine to which thesystem is connected. The upper rim region of the first tubular portionof the tubular member may define a predetermined height corresponding toa maximum amount of liquid filter medium to be placed in the housing.The means for inhibiting suction of filter medium may further comprise asecond tubular portion of the tubular member, having a widthpredominantly less than the width of the inner treatment chamber of thereservoir top. The second tubular portion of the tubular member mayemanate from and extending above the first tubular portion of thetubular member, to an elevation higher than the outlet of the innertreatment chamber of the reservoir top, when the housing and at leastone baffle member are assembled, so that the housing may be tipped up toa predetermined angle, without having filter medium reach the outlet ofthe housing.

Means may be provided for returning liquid filter medium, that may becarried out of the inner treatment chamber of the reservoir base andsubsequently condense in the inner treatment chamber of the reservoirtop, to the inner treatment chamber of the reservoir base. The means forreturning filter medium may further comprise a top wall of the innertreatment chamber of the reservoir top, contoured to have a low pointdisposed above the open top of the tubular member, so that filter mediumthat may condense on an inner surface of the top wall of the innertreatment chamber will be prompted to collect and drip off from the lowpoint, back into the inner treatment chamber of the reservoir base. Themeans for returning filter medium may further comprise an aperture inthe second tubular portion of the tubular member, for permittingcondensed liquid filtering material that may become trapped between thesecond tubular portion of the tubular member and the wall of the innertreatment chamber of the reservoir top, to flow back into the innertreatment chamber of the reservoir base.

Preferably, the cross-sections of each of the first tubular side wall,the second tubular side wall, the third tubular side wall and thetubular side wall of the tubular member have a common configurationselected from the group of shapes consisting of: cylindrical,rectangular, triangular. The housing may comprise a substantially hollowreservoir operably configured for receiving and containing a liquidfilter medium. The at least one baffle member may comprise anopen-topped tubular member, disposed within the housing, and defining agenerally cylindrical inner treatment chamber and a generally annularouter treatment chamber.

The apparatus may further comprise a fluid separator member, operablydisposed between the housing and the at least one baffle member, forpartitioning the generally annular outer member into a first annularouter member in direct fluid communication with the inlet to thehousing, and a second annular outer member in direct fluid communicationwith the outlet from the housing. At least one circumferentiallyextending baffle wall may emanate upwardly from the at least one bafflemember toward a top wall of the housing. At least one circumferentiallyextending baffle wall may emanate downwardly from a top wall of thehousing toward the at least one baffle member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of the apparatus for the treatment ofgases in a positive crankcase ventilation system, according to apreferred embodiment of the present invention.

FIG. 2 is a side elevation, in section, of the emissions control deviceof the apparatus for the treatment of gases, according to an embodimentof the present invention.

FIG. 3 is an end elevation, in section, of the emissions control deviceof the apparatus for the treatment of gases, according to the embodimentof FIG. 2.

FIG. 4 is a side elevation, in section, of the reservoir of theemissions control device of FIGS. 2 and 3.

FIG. 5 is an end elevation, in section, of the reservoir of theemissions control device of FIGS. 2 and 3.

FIG. 6 is a top plan view of the reservoir of the emissions controldevice of FIGS. 2 and 3.

FIG. 7 is a side elevation of the reservoir of the emissions controldevice of FIGS. 2 and 3, showing the optional observation window.

FIG. 8 is a side elevation, in section, of the lid for the emissionscontrol device of FIGS. 2 and 3.

FIG. 9 is an end elevation, in section, of the lid for the emissionscontrol device of FIGS. 2 and 3.

FIG. 10 is a top plan view of the lid for the emissions control deviceof FIGS. 2 and 3.

FIG. 11 is a side elevation, in section, in an inverted position, of thebaffle plate for the emissions control device of FIGS. 2 and 3.

FIG. 12 is an end elevation, in section, in an inverted position, of thebaffle plate for the emissions control device of FIGS. 2 and 3.

FIG. 13 is a top plan view of the baffle plate for the emissions controldevice of FIGS. 2 and 3.

FIG. 14A is a side elevation, in section, of the interior inlet tube forthe emissions control device of FIGS. 2 and 3.

FIG. 14B is a side elevation, in section, of an interior inlet tube ofan alternative embodiment, for the emissions control device of FIGS. 2and 3.

FIG. 15 is a side elevation, in section, of the emissions control deviceaccording to an alternative embodiment of the invention.

FIG. 16 is an end elevation, in section, of the emissions control deviceaccording to the alternative embodiment of the invention of FIG. 15.

FIG. 17 is an exploded perspective view of the components for theelectronic ionizer for the apparatus according to a preferred embodimentof the invention.

FIG. 18 is a perspective view, partially in section, of the electronicionizer of the embodiment of FIG. 17.

FIG. 19 is a top plan view, in section, of the electronic ionizer ofFIG. 17, showing the gas maze through the ionizer electrodes.

FIG. 20 is a schematic showing how the circuit board for the electronicionizer of FIG. 17 may be laid out.

FIG. 21 is a circuit diagram for a transistor oscillator for theelectronic ionizer of FIG. 17.

FIG. 22 is a side elevation of a portion of the mounting bracket for theliquid filtering device.

FIG. 23 is an end elevation thereof.

FIG. 24 is a top plan view thereof.

FIG. 25 is a side elevation of the angle bracket member for the mountingbracket for the liquid filtering device.

FIG. 26 is an end elevation thereof.

FIG. 27 is a top plan view thereof.

FIG. 28 is a side elevation, in section, thereof.

FIG. 29 is a top plan view of the mounting bracket affixed to the liquidfiltering device.

FIG. 30 is a side elevation of the bracket members in one orientation.

FIG. 31 is a side elevation of the bracket members in an alternativeorientation.

FIG. 32 is a side elevation of the bracket members in a furtheralternative orientation.

FIG. 33 is a side elevation in section of the liquid filter mediumreservoir according to a further embodiment of the invention.

FIG. 34 is a side elevation in section of the base of the reservoir ofthe embodiment of FIG. 33.

FIG. 35 is side elevation in section of the reservoir top of theembodiment of FIG. 33.

FIG. 36 is a side elevation in section of the baffle for the liquidfilter medium reservoir of the embodiment of FIG. 33.

FIG. 37 is a side elevation of the baffle for the liquid filter mediumreservoir of the embodiment of FIG. 33, showing the flow path of thegases being filtered.

FIG. 38 is a top plan sectional view taken along lines 38-38 of FIG. 33.

FIG. 39 is a side elevation in section of the liquid filter mediumreservoir, having liquid filter medium in it when the vehicle engine isnot running.

FIG. 40 is a side elevation, in section of the liquid filter mediumreservoir of the embodiment of FIG. 33, with liquid filter mediumtherein, shown during a steady state motor running operating conditions.

FIG. 41 is a side elevation, in section, of a liquid filter mediumreservoir according to another alternative embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

While this invention is susceptible of embodiment in many differentforms, there are shown in the drawings and will be described in detailherein, several specific embodiments, with the understanding that thepresent invention is to be considered as an exemplification of theprinciples of the invention and is not intended to limit to theinvention to the embodiments illustrated.

FIG. 1 is a schematic illustration of the apparatus 20 for the treatmentof gases in a positive crankcase ventilation system, according to apreferred embodiment of the invention. Apparatus 20 is configured to beretrofitted into existing internal combustion engine systems, althoughit may be suitably modified for inclusion as original equipment, withoutdeparting from the scope of the present invention. Apparatus 20 includesemission control device 25, connected to engine 30 by hose adapter 35and hose 40. Hose adapter 35 is configured to be insertingly receivedinto the engine 30 at the original PCV valve location 36. The originalPCV valve 45 for engine 30 is connected, by a suitably sized hose, forexample, to the outlet of emission control device 25 and by hose 50 toelectronic device 55, which is an electronic ionizer, through which the“cleaned” gases are passed. Electronic device 55 is, in turn, connectedby hose 60 to the PCV vacuum port 65 at the intake manifold/carburetor67 of the internal combustion engine. In the absence of the system ofthe present invention, the conventional route of the crankcase emissionsmaterials is directly from the PCV port on the engine, to the vacuumport, as indicated by the broken line in FIG. 1.

FIGS. 2-14A, 14B illustrate the emissions control device 25. Reservoir70 and lid 75 form a tank for holding a liquid filtering medium.Cylindrical inlet 80 and outlet 85 are formed in lid 75. Inlet fitting90 is preferably threadably received in inlet 80, while outlet fitting95 is preferably threadably received in outlet 85. Baffle plate 100,which has a gasket member 105 affixed to its peripheral edge, isinsertably and frictionally received in lid 75. It is important thatgasket member 105 make a substantially air- and liquid-tight sealbetween lid 75 and baffle plate 100, in order to facilitate the drawingof crankcase emissions materials through the device 25 and on throughthe remainder of the treatment system. In addition, the seal is neededto help prevent loss of the filtering solution through spillage andseeking which might be prompted, for example, by vibration of theengine. Preferably, gasket 105 is fabricated from a fluoropolymer with ahardness of 40-50 on a durometer test. Fastener rod 110 is preferablythreadably or otherwise fixedly received at its lower end in a boss 115in reservoir 70. The upper end of fastener rod 110 passes throughaligned holes in baffle plate 100 and lid 75, and is threaded, toreceive a fastener, such as wing nut 120. In order to ensure that asuitably tight seal is created, the wing nut 120 may be tightened snuglyby hand.

Preferably, reservoir 70, lid 75, and baffle plate 100 are allfabricated from a durable plastic material, which will be capable ofwithstanding the heat and vibration associated with a car enginecompartment environment. In addition, the material from which reservoir70, lid 75, and baffle plate 100 are fabricated should be capable ofresisting attack by the crankcase emissions materials which will bepassed through it, as well as attack by the chemicals in the solutionwhich will be stored in it, as described in further detail herein.

FIGS. 5-7 illustrate reservoir 25 in further detail. In a preferredembodiment of the invention, reservoir 70 is fabricated from asubstantially opaque material. A window 71, shown in broken lines, maybe provided to permit visual inspection of the level of liquid solutionin the emissions control device 25. Alternatively, reservoir 70 may befabricated from a transparent or translucent material, to enable visualinspection of the liquid solution to be contained therein. Regardless ofits configuration, the reservoir should be resistant to chemical orphysical deterioration in its given environment.

The structure of lid 75 and baffle plate 100 is configured to forcecrankcase emissions materials, received through inlet 90, through theliquid solution held in emissions control device 25. Reservoir 70preferably will be filled with a liquid solution to a level rangesubstantially flush with the lower end of the open tubular boss 130 inbaffle plate 100. The inside surface of reservoir 70 may carry indiciacorresponding to the numerical value of the volume of liquid solution inthe reservoir. If reservoir 70 should happen to be fabricated fromtransparent or translucent material, or have a transparent ortranslucent window, indicia may placed on the outside surface of thereservoir.

FIGS. 8-10 illustrate the lid 75, which includes inlet 80 and outlet 85.Preferably, a polymer filter may be insertably received within outlet85. Alternatively, an atomizer disc may be provided on the lower end ofoutlet 85, to prevent the mass passage of liquid solution out throughthe outlet 85, which might otherwise occur as a result of the suctionplaced on the emissions control device 25 by the vacuum from the vacuumport.

FIGS. 11-13 illustrate the baffle plate 100. Baffle plate 100, which isshown upside down in FIGS. 11 and 12, includes peripheral edge 125,inlet boss 130 and intermediate boss 135. Inlet boss 130 insertablyreceives interior inlet tube 140 (FIG. 14A), which preferably is alsoconfigured from a plastic or similar material. Intermediate boss 135 ispreferably configured to receive a polymer filter for precluding passageof liquid solution or large droplets thereof, and to restrict passage ofmist or vapor. Alternatively, an atomizer disc may be positioned at anend of intermediate boss 135.

In a preferred embodiment of the invention, in order to further ensurethat the flow of gases is properly directed and that there are no leaks,in addition to the gasket 105, an elastomeric grommet 106 is provided,in the aperture 107 in baffle plate 100. Grommet 106 is toroidal, sothat fastener rod 10 passes through grommet 106.

When the emissions control device is installed to an internal combustionengine, it is important that the emissions control device be installedbetween the crankcase of the engine and the PCV valve. Relocation of thePCV valve downstream of the emissions control device prevents rapid oruncontrolled evacuation or loss of the solution that may be present inthe tank for holding a liquid filtering medium, due to increased vacuum.In addition, retaining the PCV valve prevents increased reduction of theboiling point of the solution due to the less relative loss of pressure(higher vacuum) controlled by the PCV valve. Other physicalcharacteristics of the solution and PCV pollutants, such as vaporpressure and condensation may also be affected by higher relativevacuum. By locating the reservoir upstream of the PCV valve, vacuum islimited to that controlled by the original equipment valve.

A universal type plastic connector will be used for installation of theemissions control device 25 in the original PCV location. The connectormay be of a hose barb type (similar to the connection ends of the inletand outlet fittings shown in FIG. 3) to allow automotive tubing or hoseto be attached to provide the gaseous connection required between theoriginal PCV location and the emissions control device. The inletfitting 90 to the emissions control device 25 is also a hose barb typeconnection, preferably a right angle, that allows automotive hose to beused for gaseous communication of crankcase emissions with the device25. This hose barb connection is screwed into the lid 75. The inletfitting 90 and lid 75 are in communication with interior inlet tube 140,which provides a number of functions for the device 25.

The functions of interior inlet tube 140 include:

1) provision of gaseous communication of crankcase emissions with thesolution to be contained in device 25 and other materials which may beplaced within the device 25;

2) provision of pressure relief and gas by-pass to control aeration ofthe solution in the device 25, to control solution loss and eliminateany hydraulic back pressure to the crankcase during engine start-up andoperation;

3) provision of fail safe forward motion of crankcase emissions in caseof freezing or other blockage in the device 25 due to poor maintenance,neglect or damage;

4) provision of back-flow prevention to eliminate the possibility of thesolution, etc. to be drawn back into the crankcase due to dieseling,back-fire or other condition that could cause a reversal of gas flow.

The interior inlet tube 140 is located toward one end of the interior ofdevice 25. This allows the solution to mix in a circular motion duringthe aeration process. This also allows fluid movement over catalyticmaterials which may be located in the device 25, and also providescontinuous mixing of the solution with crankcase emissions.

Crankcase emissions materials are diverted 90° from the direction oftravel at the elbow of the inlet fitting 90. This provides the firstinertial break for particulate matter and/or oil/fuel droplets travelingin the gas hose. These materials will hit the elbow wall causing rapiddeceleration of the solid/liquid material. Crankcase emissions materialswill then travel downward into the interior inlet tube 140 which extendsbelow the level of the liquid solution, to a position near the bottom ofthe device 25. The solid and liquid material contained in the crankcaseemissions materials then hit the liquid and the bottom of the device ina direction 180° from the outlet of the device 25 and become trapped inthe device 25.

The interior inlet tube 140 is vented (141) into the device 25 near thetop tangent to the vertical flow direction. This vent is located abovethe solution level and baffle plate 100 to provide the pressure relief,aeration control and back-flow prevention described above. That is, ifthe solution were to freeze, the suction from the intake of the enginewould still be able to pull some of the crankcase gases through theapparatus, bypassing the frozen solution. In addition, since it is knownthat the direction of the vacuum can, during the engine cycle, reverse(although the magnitude of the reversed suction is not as great as themagnitude of the normal suction flow) the vent 142 prevents thecrankcase from exerting sufficient suction to draw gases and/orfiltering solution into the crankcase.

The preferred horizontal gas flow through the vent is 360° from the flowdirection in the PCV hose or 180° from the elbow particle impact area.This vent is sized to maximize gaseous communication of the reservoirsolution without physical loss of the solution downstream. The interiorinlet tube 140 further contains openings 142 at the bottom of the tubeto provide direct crankcase gas, vapor, particle, etc., contact with thesolution. The number and size of the openings may vary and are may bedistributed around the tube. Radially directed openings may also beprovided near the bottom of tube 140, and may also be provided atseveral levels above the bottom of the tube. The interior of the end oftube 140 may be conical (such as may be formed by machining the interioropening of tube 140 from a solid piece of material. Alternatively, theinterior of the end of the tube (e.g., tube 140′) may be substantiallyflat, as seen in FIG. 14B.

The preferred solution to be used in device 25 will comprise a mixtureof uninhibited food grade or USP grade 1,2-dihydroxypropane and water.The dihydroxypropane (propylene glycol) is a type of anti-freeze. Thefreeze point of this material is on the order of −76° F., depending uponthe mixture to provide freeze protection in cold climates. A traceamount of methyl, ethyl, isopropyl, butyl or other alcohol may be addedto the solution to improve the solubility of the fuel, oil, sludge andvapors with the solution. Ethyl and isopropyl are preferred due to thesolubility of these alcohols with gasoline and water. Ethyl alcohol isused to make gasohol blended gasoline fuel. Isopropyl alcohol is used ingas line antifreeze and will not cloud, like methanol.

Uninhibited food or USP grade propylene glycol is used due to lowtoxicity, environmental compatibility (before mixing with oil, sludgeand other contaminants) and lack of dye, color and antioxidants. The USPgrade is preferred due to reagent purity.

The water mixed with the glycol will be purified water with a minimumspecific resistance of 100,00 ohm-centimeter at 25° C. for the system ofthe present invention. Purified water at 100,000 ohm-centimeter isconsistent with water having less than 5.0 ppm total ionized solids.This water may be prepared by reverse osmosis, distillation,deionization or a combination of all three methods, and should containless than 10.0 ppm silica as SiO₃. Water with an ionic content greaterthan 5.0 ppm may interfere with the electronic ionizer locateddownstream of the chamber, particularly if divalent cations are presentin the water.

The mixing action of the fuel, oil, sludge, etc., and glycol is based onthe chemical principle that like materials dissolve like materials. Forexample, motor oil is soluble in gasoline, gasoline is soluble inalcohol and glycol, and alcohol and glycol are soluble in water. Theresults of mixing the above-listed components is an emulsion of oilyfuel, glycol/alcohol and water. This emulsion contains a large amount ofminute oily droplets of oily fuel that remain separated into smalldroplets even after aeration or agitation has stopped. This effect issimilar to that caused by the use of soap or detergent on suchmaterials, but does not produce foam or lather in the process. Thecreation of the emulsion results in an exponential increase in thesurface area contact between the oily fuel and glycol that greatlyincreases the oxidation potential (breakdown) of the oil. The fractionsthat completely mix will have a reduced flash point. Any fraction thatdoes not completely dissolve will also burn easier due to the size ofthe suspended particles (droplets) and the fact that the undissolvedfractions are surrounded by more flammable material. Glycol vapors andmist are combustible. Oily fuel and glycol vapors/mist mixed togetherare also combustible. The water present serves to retard the system and,in combination with the glycol, helps to limit evaporation. All of theforegoing materials in the solution are environmentally safe andnon-toxic, prior to contact with the engine emissions.

During operation of the device 25, the oily fuel droplets are atomizedas an aerosol with the glycol/water vapors. This provides a vapor ormist from the device 25 that has a substantially reduced flash point ascompared to direct oil/gasoline mixtures, particles and sludge from astandard PCV system. In other words, by dispersing the heavy oils andgasoline into the solution and dissolving some of the hydrocarbon andgases into the solution, combustion is easier to achieve by passivecontrol. The fumes, vapors and mist exiting the device 25 have a lowerand more consistent flash point range. Without the device 25, theconcentrations of oil and gasoline reaching the combustion chamber aresubstantially uncontrollable. Heavy high flash point oils may reach thecombustion chamber intermittently with lower flash point fuel and gases,which may interrupt even combustion.

The glycol contains 42% oxygen by weight. Ethyl alcohol contains 35%oxygen by weight. Carbon monoxide and carbon dioxide will be absorbedinto the solution at a rate that is equivalent to the partial pressurefor each compound. This absorption will be limited by the pressure orlack of pressure available within device 25. Carbon dioxidedisassociates in water solutions to form carbonic acid. This furtherincreases the amount of oxygen in the solution. Nitrous oxides aresparingly soluble in water and alcohols. However, oxides of nitrogenwill support combustion via the oxygen content of the compound. Byincreasing the amount of available oxygen in the solution, the potentialfor efficient combustion is increased. Furthermore, by maintaining ahigher level of oxygen for combustion, to a point, further production ofoxides of nitrogen are limited. Oxidation of the hydrocarbons (oilyfuel) in the gases will also begin in the solution prior to combustion.

Reagent grade hydrogen peroxide, ACS grade of variable strength, but nogreater a strength or concentration than about 8% by weight, may also beadded to the solution as part or all of the water fraction. 3% by weightis preferred. Peroxide added to the solution will provide a strongoxidizing agent that will assist in the breakdown of organic compoundsin the solution. Peroxide in greater strength will decompose the glycoland other organic material too quickly. The peroxide will also increasethe oxygen content in the solution.

A preferred formulation of the liquid filtering solution could be asfollows:

37% by volume water (deionized and purified as described hereinabove),

55% by volume propylene glycol,

5% by volume ethyl and/or isopropyl alcohol, and

3% by volume hydrogen peroxide solution (3% by wt.), although theconstituencies and proportions of the liquid filtering solution may bevaried as required by the particular application and/or availability ofmaterials.

Catalytic materials may also be placed in the solution to assist withthe breakdown of crankcase organic materials. These catalytic materialsmay include dissimilar metals that will create a galvanic cell whenexposed to water. The galvanic cell function (corrosion) will generatehydroxyl free radicals in the solution. In doing so, depending on thetypes of metals used, multivalent metal cations may also be releasedinto the solution. In too high a quantity, the multivalent cations mayinterfere with the ionization electrodes downstream. Therefore, thedissimilar metals used for the galvanic cell should be relatively closetogether in the galvanic series to limit the rate of corrosion.

An example of dissimilar metals in this solution that would be lessdesirable, though functional, would be copper and aluminum. An examplethat would be more desirable would be a zinc-copper pairing. Thepreferred material(s) would consist of dissimilar metals that arelocated closer together in the galvanic series. This would create a muchlower and slower oxidation/reduction potential in the device 25 andprovide better control of the system. Aluminum and copper are quite farapart in the galvanic series and under certain conditions mayself-destruct rapidly. Metals such as tin and naval brass would providea suitable, less active, galvanic cell.

There are metal alloys available, such as KDF 55 Process Medium and KDFwool that will provide the oxidation/reduction potential required toassist in the breakdown of organic crankcase emissions materials. Thismaterial is made of zinc and copper in ratios that provide efficientoxidation/reduction potential when contacted with water. This materialis typically used in water purification, and the mechanisms for breakingdown organic materials in the crankcase emissions materials are similar.Strontium and barium ferrite, magnetic or non-magnetic, will alsoproduce hydroxyl radicals in solution.

The purpose of the catalytic materials is to produce hydroxyl freeradicals (OH—) in solution. Hydroxyl radicals are efficient at breakingdown organic compounds in aqueous solutions. The ability of hydroxylfree radicals to destroy organic compounds is known. The ultimatebyproducts of the destruction of light organic materials by hydroxylfree radicals are carbon dioxide and water. However, the heavy oilswhich may be present in crankcase emissions materials will be brokendown into smaller, lower flash point molecular weight compounds duringthe oxidation/reduction process. This will produce lower molecularweight intermediate organic compounds in the reservoir, which have lowerflash points. Even when the engine is shut off, these chemical reactionswill continue to take place in device 25.

As a practical matter, because the crankcase gas velocities are high,and the residence time in the device 25 is short, completebreakdown/conversion of the organic materials in the crankcase emissionsmaterials by device 25 is a practical impossibility, for any devicesized to be usable in a consumer vehicle. However, using commerciallyjustifiable materials, device 25 can and will provide marked improvementin the quality of the crankcase emissions materials.

Materials to be used for the solution should be chosen to providesuitable gas treatment characteristics, but still be reasonableeconomical. For example, the propylene glycol based antifreeze soldunder the brand name SIERRA® could be used as a solution base. Pieces ofcopper, brass or bronze metal could be used as catalytic materials.Copper oxides formed by any copper containing materials can be used toassist in the destruction of oxides of nitrogen. Gold and platinummaterials can be used, if economically justified.

Once the crankcase emissions have entered the device 25 and solution,essentially all the heavy hydrocarbon and particulate matter will betrapped in the device 25. Thus, only the lighter hydrocarbons and gaseswill be able to escape device 25 to proceed to the intake manifold. Thelighter hydrocarbons should consist mainly of a lower flash pointmixture of hydrocarbon vapor, mists and gases. This provides control ofthe crankcase emissions at a level more suitable for combustion, thusreducing emissions and increasing fuel economy.

The baffle plate 100 in device 25 ensures prevention of directaspiration of the solution, when the vehicle travels on rough surfaces,or steep or tilted surfaces. In the event that the solution is splashedagainst the underside of baffle plate 100, a filtration device will belocated in intermediate boss 135, having preferably a 225 micron nominalpore size may be provided. This will prevent particles from passingabove the baffle plate. Liquid that passes above the baffle plate willbe prompted to drain back into the reservoir. The angles and elevationof the baffle plate filter will tend to prevent direct aspiration ofsolution into the outlet fitting 95 of device 25. Outlet 85 of lid 75may also be provided with a filtration device having preferably a 225micron nominal pore size may be provided. Any liquid reaching thislocation will be atomized into small droplets when subjected to thevelocity of the exit gases from device 25.

A preferred filter device may be obtained from Porex Industries, and isfabricated from polypropylene. Alternatively, a metal screen having asubstantially similar nominal pore size, may be used.

FIGS. 15-16 illustrate an emissions control device 25′ according to analternative embodiment of the invention, wherein elements having similarstructure and function to those of the embodiment of FIGS. 2-14A, 14Bare provided with like reference numerals, augmented by primes (′).Device 25′ is provided with a substantially flat baffle plate 100′, witha large aperture 130′ for receiving interior inlet tube 140′, and aplurality of smaller intermediate apertures 135′. Interior inlet tube140′ has a stepped configuration at its lower end, with apertures 142′extending in both axial and radial directions.

As the vehicle is operated, there will be some attrition of the solutionlevel in device 25, over time, as a result of evaporation, and/orchemical reaction. Solution may be added as needed to maintain the leveldetermined to be appropriate for the device, as sized to the particularengine. However, a complete change-out of the solution, and a cleaningof the interior surfaces of the device, will be necessary from time totime, in order to remove oily residue and particulate materials from thereservoir. Preferably, device 25 should be sized, so that under normaloperating conditions and assuming normal usage, the solution should becompletely changed approximately as often as the crankcase oil itself ischanged, e.g., every three months or three thousand miles driven.

In addition to the physical and chemical treatment of crankcaseemissions materials which is performed by device 25 (25′), it has beendetermined that treatment of the “cleaned” gases leaving the device 25(25′) by electronic ionization also has beneficial effects. Accordingly,in addition to the device 25, the apparatus for the treatment ofcrankcase emissions materials may also include a device for theelectronic treatment of crankcase emissions materials. FIGS. 17-21illustrate an ionizer apparatus used in association with the presentinvention.

Ionizer 55 comprises base 155, with maze walls 160 and 165, and diagonalwall 167, on the inlet side of ionizer 55. The inner surfaces of theperipheral walls of base 155 may be provided with ledges 170, upon whichintermediate wall 175 may rest. Intermediate wall 175 may also rest atopthe upper ends of walls 160, 165, 167 to form charging chamber maze 178.Intermediate wall 175 has a plurality of apertures 180, through whichion emitter pins 185 project, into charging chamber maze 178, betweenwalls 160 and 165. Emitter pins 185 project from circuit board 190,which is covered by cover 195. Base 155 includes inlet fitting 200 andoutlet fitting 205, which connect with corresponding apertures in thewalls of base 155. Maze walls 160 and 165 have apertures 210 and 215,respectively, for permitting passage of gases through maze 178. When thecomponents of ionizer 55 are assembled, preferably with at least base155 and cover 195 being fabricated from a durable plastic material andwhich can be sealing affixed to one another, an air-tight passage isformed. It is believed that the construction of maze walls 160, 165, anddiagonal wall 167, induce a swirling action to the flow of “cleaned”crankcase gases through the ionizer, optimizing the charging of thegases, vapors, etc. passing through the ionizer. Although a particularmaze configuration is shown herein, the configuration may be modified,in accordance with the requirements of a particular application, and notdepart from the principles of the present invention, if a swirlingmotion is produced.

The components of circuit board 190 preferably comprise a direct currentto alternating current converter 220, the function of which is to changeDC voltage, available in an automotive application, to AC voltage, to beamplified through transformer 225, with a suitable voltage amplificationfactor to provide voltage and current to multi-stage, capacitivecoupled, series connected diode array voltage multiplier 230, arrangedto provide an optimum particle charge to emitter pins 185. Emitter pins185, as stated earlier, project into charge chamber maze 178. Crankcaseemissions materials flowing through maze 178 are forced, by thecontoured surfaces, to swirl and counter-swirl, prompting maximumcontact with the emitter pins 185. Maximum contact prompts maximumcharging of the gas and gaseous particles. Thus an optimum quantity ofcharged particles will be generated for transport to the intake airstream.

Carefully consideration of component parts must be made in order toavoid degradation of and/or interference with engine control onboardcomputer or other electronic device used in or about the vehicle. Propershielding, feedback protection and isolation are important. It isbelieved that frequencies of 15-20 kHz are appropriate and shouldpresent no significant difficulties with respect to interference issues,although other frequencies may be used, as desired and/or othercharacteristics of the vehicle or other apparatus, into which theinvention is to be installed, dictate.

It is believed that voltages for generating a significant suitablycharged field can be as low as 600v. Voltages in the range of 1200-8000vare believed to be optimal for achieving the desired performance,although any ionizing voltage will have some effect.

FIGS. 21 illustrates a possible circuit schematic for the oscillatorcircuitry for the ionizer. Although desired numerical values for variouscomponents have been provided, one of ordinary skill in the art, havingthe present disclosure before them, will be able to modify thesecircuits and vary the numerical values, to produce suitable ionizerapparatus, without departing from the scope of the invention. Inaddition, the particular configuration and placement of the electricalconnections may be modified without departing from the scope of theinvention.

The electronic device 55 of the present invention may be used inconjunction with the liquid treatment device 25, in a positiondownstream from device 25. Alternatively, electronic device 55 may beused by itself in the flow path from the PCV valve to the intake vacuumport, although cleaning of the electronic device 55 to removeoily/particulate deposits will be required more often than if device 55were used in association with liquid treatment device 25.

Unlike prior art devices, which may have incorporated both liquidfiltering and electronic ionization apparatus, within a single bulkyhousing, the present invention separates these two functions, into twoseparate units. This enables the ionizer to be positioned downstream ofthe liquid filtering unit, and downstream of the PCV valve itself, aswell. In addition, the construction of the present invention permits theionizer unit to be positioned as closely to the intake manifold/throttlebody, as physical space limitations and the heat of the engine permit.In this way, the volume and strength of the field of charged particlesis increased. The farther the ionizer is positioned from the intakemanifold, etc., the more likelihood there is that the charged gases andgaseous particles will lose their charge. Ideally, a linear distance ofapproximately 1 foot upstream from the intake manifold, if feasible, isdesired. Some of the advantages believed to result from the ionizationof the gases is that the combustible elements of the crankcase emissionsmaterials are prompted to be more easily combusted, and that a“cleaning” action is induced in the combustion system, prompting cleanerburning and the expulsion or removal of hydrocarbon deposits andinhibition of corrosion.

The present invention also comprises a mounting system configured forthe mounting of the emissions control device, as illustrated in FIGS. 2,3, 22-32. The mounting system comprises a first flat bracket 240 thatmounts to lid 70 and is able to adjust fore and aft about the “z” axisvia a plurality of mounting holes 245 and is also able to adjustangularly about the horizontal “x” axis by rotating the bracket aboutthe selected mounting hole. A second angled bracket 250 is attached tothe flat bracket 240 with a screw 257 that passes through apertures 241and 242 in tabs 243, 244 of bracket 240, and through one of apertures251, 252 on tabs 253, 254, respectively, of bracket 250. Brackets 240,250 may be fabricated from any suitable material, such as metal ordurable plastic. The connection acts as a hinge and is able to adjustangularly about the vertical “y” axis. A toothed lock washer 256, suchas are known in the fastener art, is placed at one end of screw 257, tobe in compression between one of tabs 253, 254, and one of tabs 242, 243to provide a gripping force, once screw 257 has been tightened down, tohelp hold bracket 240 in the selected angular position relative tobracket 250. In the embodiment as illustrated in FIG. 29, the end ofscrew 257 is threaded, and the interior of aperture 241 is likewisematingly threaded, to engage with the end of screw 257.

One of tabs 253, 254 can be selected that will allow for mounting eitherin a horizontal or vertical position relative to bracket 240. Inparticular, each of tabs 253, 254 permits positioning of bracket 240, ina range of angular positions, relative to bracket 250. The range ofpositions available when tab 253 is used, centers around a positionwhich is substantially perpendicular to the position around which therange of positions centers, when tab 254 is used. The design allows foradjustments in the “x”, “y” and “z” axes and gives maximum versatilitythereby allowing for the device 25 to be mounted in many differentengine compartment configurations in many different vehicles.

Bracket 250 is also provided with two apertures 258, which areconfigured to enable attachment of bracket 250 to a structure within theengine compartment, by bolts or metal screws, for example.

FIGS. 30-32 illustrate three potential orientations of brackets 240 and250, which can be obtained.

A typical installation procedure for the apparatus of the presentinvention is as follows.

1. Locate and remove original PCV valve and hose.

2. Mount the device 25 in a suitable location, allowing access to theinlet and outlet fittings.

3. Install the hose adapter in the original PCV grommet.

4. Route a section of new PCV hose from the previously installed hoseadapter to the device inlet fitting using suitable fittings and clamps.The device 25 should be mounted so that the inlet and outlet fittingsare substantially upright and on top.

5. Install the proper size outlet fitting into the device 25 outletport, connect a short length of either ½″ or ¾″ ID hose, to match thePCV valve OD, to the outlet elbow then install the original PCV valveinto the hose, route a new PCV hose from the PCV valve to the PCV portat the intake manifold. Locate a suitable location for the electronicassembly and install it in the PCV hose between the PCV valve and theengine. Use nylon tie straps to secure hoses and wires for a neatinstallation. Clamp all hose connections.

6. Remove the top section of the device 25 by removing the wing nut andfill to the operating level with the solution as selected.

7. Connect the negative/black lead from the ionizer unit 55 to a goodvehicle ground, connect the positive/red lead to a circuit that has+12vDC with the ignition key in the run position.

8. Check hose routing for interference, start engine and run for 30seconds, stop the engine and check for leaks.

The apparatus of the present invention is believed to improve emissionsby reducing the production of unburned or incompletely burnedhydrocarbons, carbon monoxide and oxides of nitrogen. Improvement infuel efficiency is also believed to result.

FIGS. 33-40 illustrate a further embodiment of the liquid filter mediumreservoir which is configured for improved resistance to spillage of theliquid medium, as well as improved resistance to siphoning of the liquidinto the engine.

FIGS. 33-40 illustrate the components of the liquid filter mediumreservoir. Each of the components of the liquid filter medium reservoir,according to one preferred embodiment illustrated in FIGS. 33-40, are,except as specifically noted herein, generally circumferentiallysymmetrical and radially symmetrical about a common vertical axis V(FIG. 33) of liquid filter medium reservoir 300. Reservoir 300 includesa base 303. Base 303 is formed as a cylindrical cup, having a raisedportion 306 in the bottom 309. The interior surface of lip 312 isthreaded on its inner surface. Female threads 315 on base 303 mate withmale threads 318 of top 321.

Reservoir top 321 is divided by interior cylindrical wall 324 intocentral cylindrical region 327 and surrounding annular space 330.Cylindrical passage 333 enters from one side of top 321 and communicateswith annular space 330. Another cylindrical passage 336 enters from anopposite side of top 321 and communicates with central cylindricalregion 327. As previously indicated, top 321 is configured to be screweddown into and onto base 303 so as to create a substantially fluid tightseal where top 321 meets and joins to base 303. The upper surface 339 oftop 321 is conically concave, and includes a central aperture 342 whichmay be internally threaded to receive a threaded screw plug 345, thefunction of which will described in further detail hereinafter.

An O-ring gasket 317 is positioned between top 321 and base 303.Preferably, gasket 317 will be fabricated from neoprene or some othersynthetic material, such as Bunna-N, which is resistant to attach fromoil, antifreeze, and the like.

Baffle member 348 is received within reservoir top and bottom 321, 303and held by wall 324 of top 321 against the bottom 309 of base 303.Baffle member 348 comprises a first narrow cylindrical portion 351, atruncated conical portion 354 and a bottom cylindrical portion 357. Boththe top end 360 and bottom end 363 are open. Conical portion 354intersects the top of cylindrical portion 357 at a position below topedge 366 of cylindrical portion 357 to define a gutter 369. The bottomedge 372 of wall 324 is beveled at an angle substantially equal to theangle of the conical portion 354 of baffle 348. Similarly, the bottomedge 375 of baffle 348 preferably is beveled at an angle substantiallyequal to the angle of the sides of raised portion 306 of bottom 309 ofbase 303. Base 303, top 321 and baffle member 348 are all preferablysized, so that for assembly of reservoir 300, baffle 348 is placedwithin base 303 so that the bottom 363 of baffle 348 fits snugly aroundraised portion 306. Top 321 is then placed onto base 303 and the twocomponents are screwed together. As top 321 is screwed down onto base303, bottom edge 372 of wall 324 enters into sill 369 and the beveledbottom edge 372 of wall 324 engages the side of conical portion 354. Asthe tightening is continued, top 321 pushes down on baffle 348, which inturn pushes baffle 348 down onto and against the sides of raised portion306 of base 303. Upon sufficient tightening, substantially liquid-tightseals are created between bottom edge 372 of wall 324 and the outersurface of conical portion 354 of baffle 348, and between the bottombeveled edge 375 of baffle 348 and the sides of raised portion 306 andbottom 309. The compressibility of gasket 317 permits the top and baseto be screwed together tightly enough to create the seals.

As an alternative to the use of a screw-threaded connection between thereservoir top and the reservoir base, it may be desirable, for economicreasons, to simply permanently attach the top and base, such as bycementing, sonic or heat welding, friction welding, coining, etc. Such aconstruction would not be freely openable, to permit total accesscleaning, but suitable ports (filled by threaded plugs, etc.) may beprovided for rinsing with cleaning agents.

In addition to top opening 360 and bottom opening 363, baffle 348preferably includes a drain-back hole 378, a plurality of top apertures381 and a bottom aperture 384, the purposes of each of which will bedescribed hereinafter.

A liquid filtering medium is introduced into the assembly, either priorto assembly or after, through aperture 342. The level of the liquid,with the engine turned off, would preferably be up to the tops of topapertures 381 as indicated by reference numeral 387 in FIG. 39. Inlet333 would be connected to the output from the positive crankcaseventilation valve opening in the engine while outlet 336 would beconnected to the line leading to the replaced positive crankcaseventilation valve so that the flow of gases through the inlet and outletare indicated by the arrows in FIG. 39.

Once the engine has been turned on, as indicated in FIG. 40, the suctionimposed upon the outlet 336, combined with the positive back pressuregoing into the inlet from the positive crankcase valve opening willcause the liquid level inside the baffle to rise while the liquid levelin the annular space between the baffle and the base drops. Thus, theliquid level within the walls of the baffle rises to a position abovethe top apertures 381. The flow of gases through reservoir 300 isillustrated by the arrows in FIG. 40. The gases will flow into inlet 333downward in the space between wall 324 of top 321, the cylindrical wall357 of baffle 348 and the inner surface of base 303.

The presence of bottom aperture 384 creates the liquid leveldifferentiation shown in FIG. 40, drawing the liquid inside the bafflemember 348 above the level of top apertures 381, so long as the originalliquid level is approximately the level of the top apertures 381. In apreferred embodiment of the invention, the top and bottom aperturediameters should be on the order of {fraction (3/32)}-in. diameter. Ifthe apertures become significantly larger, then the flow of gases drawnthrough the apertures may not be as fast.

A plurality of top holes are required, so that the minimum flow raterequirements of the PCV system can be accommodated. In the embodiment ofFIGS. 33-40, the majority of the PCV gases would be expected to passthrough the top apertures, although some percentage will pass throughthe bottom aperture. A plurality of spaced small top holes, in thevicinity of the static liquid level, is believed to be more effective,in view of the level differentiation (in running mode), in causing gasflow through the filter medium, than the use of one or only a few largerapertures. In addition, spreading the top apertures around thecircumference is also accommodation for the working environment of thefilter apparatus, in that vibration, sloshing caused by accelerationsand decelerations, and tilting of the housing can be expected, so atleast some of the top apertures may be partially covered by the liquidon the inside of the baffle member, at all times during such operationalperiods, even with low liquid levels.

It is anticipated the liquid filter medium will be consumed over time,as a result of simple evaporation, and through the liquid being carriedoff as vapor or fine droplets, by the gas flow. In order to slow thiscarrying-away of the vapor, it is appropriate to cause the precipitationof liquid vapor, and the provision of a tortuous path, so that gas-borneliquid droplets will collide with and collect on the interior surfacesof the housing and the surfaces of the baffle member, for drainage backto the liquid pool in the reservoir base. Accordingly, making the top ofthe baffle member higher than the exit from the housing, creates aturning path, which promotes separation of the contaminants from the gasflow.

It is believed that even if the liquid is consumed to a degree that thetop apertures will be partially or completely uncovered by liquid, inthe engine-running state, the provision of the top apertures will serveto strip the larger contaminant particles and droplets from the gasflow, thus resulting in some beneficial effect, though perhaps less thanoptimal.

The conical configuration of the top of reservoir top 321 prompts theformation of condensation droplets of the liquid filter medium. Becausethe lowest point of the conical shape is above the central axis ofreservoir 300, the droplets, when sufficiently fully formed, will fallback into the secondary liquid filter medium region.

In the embodiment of FIGS. 33-40, the reservoir base 303, the reservoirtop 321 (including walls 324 and 331), and baffle member 348, are alltubular bodies of revolution, substantially radially symmetrical abovevertical axis V. This promotes ease of manufacture, a reduction ofmaterial usage, and a consistency of operation, regardless of theorientation (about axis V) of the apparatus within the enginecompartment. However, the transverse (perpendicular to axis V)cross-sections of the components may have other configurations, such aspolygonal, rectangular, or even triangular, without departing from thescope of the present invention.

FIG. 41 illustrates still another alternative embodiment of theinvention. Filter apparatus 400 is configured to be a sealed structure,incorporating housing 402, and baffle member 404. Like the embodiment ofFIGS. 33-40, apparatus 400 is generally symmetrical about vertical axisV. Housing 402 includes inlet 406 and outlet 408. In a preferredembodiment of the invention, housing 402 may be originally formed asupper and lower halves (not shown separately), into which baffle member404 is positioned, and then the two halves are permanently sealed to oneanother. Baffle member 404 may be sealingly affixed at its bottom edgeto the bottom 410 of housing 402. Angled circumferential ledge 412sealing connects baffle member 404 to the inside surface of housing 402,except for one or more drain apertures 414. Baffle member 404 may beprovided with one or more upwardly extending circling baffle walls 416,418, 420, etc., provided with one or more drain holes 422, 424, etc.Corresponding circling baffle walls 426, 428, etc. may be provided,extending downwardly from the top of housing 402 between baffle walls416, 418, 420.

Baffle member 404 is also provided with top apertures 430 and bottomaperture 432, which operate in a manner substantially the same as thecorresponding apertures in the baffle member of the embodiment of FIGS.33-40. A downward-extending conical depression 434 may be provided inthe top of housing 402, for promoting condensation and dropping offilter medium back into the body of liquid. A threaded plug (not shown)may be received in an aperture (not shown) in the conical depression 434(as in the similar structure of the embodiment of FIGS. 33-40), forpermitting filling of the housing 402 with filter medium.

In operation, PCV gases will be drawn through the top and bottomapertures in the baffle member, and then up and down, successivelyradially outwardly past the baffle walls, until the gases reach theouter annular chamber defined by baffle wall 416, housing 402 and ledge412, and then exit the housing 402 through outlet 408. Preferably, asonly one or two of each of drain apertures 414, 422, 424 are provided,as compared to several top apertures 430, bottom aperture 432, andfurther in view of the suction being exerted on outlet 408, little, ifany of the PCV gases are pulled directly from the vicinity of inlet 406,“backwards” through aperture 414, without passing through the liquidfilter medium.

While the embodiment of FIG. 41 is illustrated and described as being acompletely sealed construction (for reduced cost and manufacturingsimplicity) and thus of necessity, disposable after a certain period ofuse, it is contemplated that an alternative embodiment may besubstantially sealed, but with a simplified removable plug or cap, toenable replenishment of the liquid filtering medium, or rinsing with asuitable solvent.

While a particular pattern of ascending and descending baffle walls isshown and described with respect to the embodiment of FIG. 41, it is tobe understood that the pattern and manner of formation of the bafflewalls may be modified (e.g., changing a wall ascending from an insertbeneath to a wall descending from a top of the reservoir), as may bedesired and/or prompted by manufacturing considerations, etc., withoutdeparting from the scope of the invention.

In addition to serving to trap hydrocarbon particulate materials throughthe use of a liquid filter medium, it is believed that even in the totalabsence or consumption of the liquid filter medium, the apparatus canstill serve to remove undesired materials from the flow of gases. Bycreating a tortuous pathway for the PCV gases through the housing, suchparticulate materials, hydrocarbon residues and the like will collidewith the baffle surfaces in the housing and collect as a form of sludgeon the interior surfaces and in the bottom of the reservoir. Among theundesirable components which will be, at least in part, separated fromthe gas flow, may be water soluble corrosives and condensates (formedthrough the action of temperature and water vapor on the petroleumhydrocarbons in the combustion gases, etc.), which might otherwise havea harmful effect upon the metal surfaces of the engine intake system andpiston and cylinder surfaces. Such corrosives may include such materialsas sulfuric acid (although the exact composition of such materials isdifficult to ascertain, being a function of the combustion mixture, andother chemicals present in the crankcase volume).

The foregoing description and drawings merely explain and illustrate theinvention, and the invention is not limited thereto except insofar asthe appended claims are so limited, as those skilled in the art who havethe disclosure before them will be able to make modifications andvariations therein without departing from the scope of the invention.

What is claimed is:
 1. A system for the treatment of crankcase emissionsmaterials, in a positive crankcase ventilation system of an internalcombustion engine, in which the crankcase emissions materials,containing at least one of partially and completely unburned hydrocarbonmaterials, oil, particulate materials and gaseous combustion byproducts,are drawn from the crankcase of the engine and directed to an air intakeportion of the engine for recirculation through and further combustionin the engine, the system for treatment of crankcase emissions materialsin a positive crankcase ventilation system comprising: a filteringapparatus, for containing a liquid filter medium, the filteringapparatus being operably configured to receive therethrough crankcaseemissions materials conducted substantially directly from the crankcaseof an internal combustion engine, for substantially separating said atleast one of said partially and completely unburned hydrocarbonmaterials, oil, particulate materials and gaseous combustion byproductsfrom crankcase emissions materials; a positive crankcase ventilationvalve, operably positioned downstream from the filtering apparatus, forregulating the pressure of crankcase emissions materials passing throughthe filtering apparatus; an electronic apparatus, operably positioneddownstream from the positive crankcase ventilation valve, for impartingan electrostatic charge to the filtered crankcase emissions materials,prior to delivery of the filtered crankcase emissions materials to theair intake portion of an internal combustion engine; the filteringapparatus further comprising a housing, having an inlet and an outlet;the inlet of the housing being operably connected, at least indirectly,to a positive crankcase ventilation outlet of an internal combustionengine, the outlet of the filter medium reservoir being operablyconnected, at least indirectly, to a positive crankcase ventilationvacuum port of an internal combustion engine; at least one bafflemember, operably disposed within the housing, and configured forconstraining introduction of the crankcase emissions materials, from thecrankcase, into at least one treatment chamber defined by the housingand the at least one baffle member.
 2. The system according to claim 1,wherein the housing comprises: a substantially hollow reservoir baseoperably configured for receiving and containing a liquid filter medium;and a reservoir top, including an inner treatment chamber, and asurrounding outer treatment chamber.
 3. The system according to claim 2,wherein the reservoir base is an open-topped treatment chamber, definedby a first tubular side wall having an upper rim, and a bottom wall; theinner treatment chamber of the reservoir top is an open-bottomedtreatment chamber, defined by a second tubular side wall having a lowerrim; and the outer treatment chamber is defined by a third tubular sidewall surrounding at least a portion of the second tubular side wall, thewall of the outer treatment chamber having a lower rim.
 4. The systemaccording to claim 3, wherein the inlet is disposed in the reservoirtop, in fluid communication with the outer treatment chamber thereof,and the outlet is also disposed in the reservoir top, in fluidcommunication with the inner treatment chamber thereof.
 5. The systemaccording to claim 4, wherein the at least one baffle member comprises:an open-topped tubular member, operably configured, upon positioningwithin the housing, for defining an inner treatment chamber of thereservoir base, that is in fluid communication with the inner treatmentchamber of the reservoir top, and an outer treatment chamber, disposedbetween a tubular side wall of the tubular member and the first tubularside wall of the reservoir base; the outer treatment chamber being influid communication with the outer treatment chamber of the reservoirtop; at least one aperture extending through the tubular side wall ofthe tubular member; the tubular member further being operably configuredfor cooperation with the reservoir top, so that upon assembly of thehousing and at least one baffle member, direct fluid communicationbetween the outer treatment chamber of the reservoir top and the innertreatment chamber of the reservoir top are substantially precluded, sothat fluid passing through the housing is constrained to pass, insuccession, into the inlet, through the outer treatment chamber of thereservoir top, to the outer treatment chamber of the reservoir base,then to the inner treatment chamber of the reservoir base, then to theinner treatment chamber of the reservoir top and through the outlet,thus passing through liquid filter medium that may be disposed withinthe reservoir base.
 6. The system according to claim 5, wherein thetubular member further comprises: a first tubular portion, having anupper rim region and operably configured to be received within thereservoir base, and having a width substantially equal to the width ofthe lower rim of the wall of the inner treatment chamber of thereservoir top; at least one abutment surface, disposed proximate theupper rim region of the first tubular portion, for engaging the lowerrim of the wall of the inner treatment chamber of the reservoir top,when the tubular member is placed in the reservoir base and thereservoir base and reservoir top are assembled, so that the reservoirtop forces a lower rim of the first tubular portion of the tubularmember against the bottom wall of the reservoir base, to createsubstantially fluid tight seals between the lower rim of the innertreatment chamber of the reservoir top and the at least one abutmentsurface, and between the lower rim of the first tubular portion of thetubular member and the bottom wall of the reservoir base.
 7. The systemaccording to claim 6, wherein the at least one aperture in the tubularmember is disposed proximate the upper rim region of the first tubularportion.
 8. The system according to claim 6, wherein the at least oneaperture in the tubular member is disposed proximate the lower rim ofthe first tubular portion.
 9. The system according to claim 6, whereinthe at least one aperture in the tubular member comprises at least twoapertures in the first tubular portion, at least a first of the at leasttwo apertures being disposed proximate the upper rim region of the firsttubular portion, and at least a second of the at least two aperturesbeing disposed proximate the lower rim of the first tubular portion. 10.The system according to claim 6, further comprising means for inhibitingsuction of liquid filter medium into the intake system of an internalcombustion engine to which the system is connected.
 11. The systemaccording to claim 10, wherein the upper rim region of the first tubularportion of the tubular member defines a predetermined heightcorresponding to a maximum amount of liquid filter medium to be placedin the housing, the means for inhibiting suction of filter mediumfurther comprising: a second tubular portion of the tubular member,having a diameter predominantly less than the diameter of the innertreatment chamber of the reservoir top; the second tubular portion ofthe tubular member emanating from and extending above the first tubularportion of the tubular member, to an elevation higher than the outlet ofthe inner treatment chamber of the reservoir top, when the housing andat least one baffle member are assembled, so that the housing may betipped up to a predetermined angle, without having filter medium reachthe outlet of the housing.
 12. The system according to claim 11, furthercomprising means for returning liquid filter medium, that may be carriedout of the inner treatment chamber of the reservoir base andsubsequently condense in the inner treatment chamber of the reservoirtop, to the inner treatment chamber of the reservoir base.
 13. Thesystem according to claim 12, wherein the means for returning filtermedium comprises: a top wall of the inner treatment chamber of thereservoir top, contoured to have a low point disposed above the open topof the tubular member, so that filter medium that may condense on aninner surface of the top wall of the inner treatment chamber will beprompted to collect and drip off from the low point, back into the innertreatment chamber of the reservoir base.
 14. The system according toclaim 12, wherein the means for returning filter medium comprises: anaperture in the second tubular portion of the tubular member, forpermitting condensed liquid filtering material that may become trappedbetween the second tubular portion of the tubular member and the wall ofthe inner treatment chamber of the reservoir top, to flow back into theinner treatment chamber of the reservoir base.
 15. The system accordingto claim 1, further comprising: means, operably disposed in thereservoir base, for facilitating the chemical alteration of at least aportion of the crankcase emissions materials.
 16. The system accordingto claim 15, wherein the means for facilitating chemical alteration ofat least a portion of the crankcase emissions materials comprise meansfor establishing a galvanic cell in the reservoir base.
 17. The systemaccording to claim 16, wherein the means for establishing a galvaniccell in the reservoir base comprises at least one material from thegroup consisting of members made of dissimilar metals in the galvanicseries.
 18. The system according to claim 1, wherein the electronicapparatus comprises: an electronic ionizer apparatus for imparting acharged particle field to treated crankcase emissions materials exitingfrom the housing for a liquid filter medium therein, the electronicionizer apparatus being operably positioned downstream from the housingfor a liquid filter medium therein.
 19. The system according to claim11, wherein the electronic ionizer apparatus further comprises: ahousing, having an inlet and an outlet, portions of the housing definingan electronic treatment chamber, the inlet of the housing being operablyconnectable, at least indirectly, to a positive crankcase ventilationoutlet of an internal combustion engine, the outlet of the housing beingoperably connectable, at least indirectly, to a positive crankcaseventilation vacuum port of an internal combustion engine; electroniccircuitry, operably associated with the housing and including at leastone emitter pin operably emanating into the electronic treatmentchamber, for producing ionic emanations for producing a charged particlefield within the crankcase emissions materials, the portions of thehousing defining the electronic treatment chamber, including one or morewall members configured for producing a swirling motion to the crankcaseemissions materials entering the electronic treatment chamber from theinlet of the housing, around the at least one emitter pin.
 20. Thesystem according to claim 1, wherein the electronic apparatus comprisesan electronic ionizer apparatus further comprising: a housing, having aninlet and an outlet, portions of the housing defining an electronictreatment chamber, the inlet of the housing being operably connectable,at least indirectly, to a positive crankcase ventilation outlet of aninternal combustion engine, the outlet of the housing being operablyconnectable, at least indirectly, to a positive crankcase ventilationvacuum port of an internal combustion engine; electronic circuitry,operably associated with the housing and including at least one emitterpin operably emanating into the electronic treatment chamber, forproducing ionic emanations for producing a charged particle field withinthe crankcase emissions materials, the portions of the housing definingthe electronic treatment chamber, including one or more wall membersconfigured for producing a swirling motion to the crankcase emissionsmaterials entering the electronic treatment chamber from the inlet ofthe housing, around the at least one emitter pin.
 21. The systemaccording to claim 5, wherein the cross-sections of each of the firsttubular side wall, the second tubular side wall, the third tubular sidewall and the tubular side wall of the tubular member have a commonconfiguration selected from the group of shapes consisting of:cylindrical, rectangular, triangular.
 22. The system according to claim1, wherein the housing comprises: a substantially hollow reservoiroperably configured for receiving and containing a liquid filter medium.23. The system according to claim 22, wherein the at least one bafflemember comprises: an open-topped tubular member, disposed within thehousing, and defining a generally cylindrical inner treatment chamberand a generally annular outer treatment chamber.
 24. The systemaccording to claim 23, further comprising: a fluid separator member,operably disposed between the housing and the at least one bafflemember, for partitioning the generally annular outer member into a firstannular outer member in direct fluid communication with the inlet to thehousing, and a second annular outer member in direct fluid communicationwith the outlet from the housing.
 25. The system according to claim 24,further comprising at least one circumferentially extending baffle wallemanating upwardly from the at least one baffle member toward a top wallof the housing.
 26. The system according to claim 24, further comprisingat least one circumferentially extending baffle wall emanatingdownwardly from a top wall of the housing toward the at least one bafflemember.
 27. An apparatus for the treatment of crankcase emissionsmaterials, in a positive crankcase ventilation system of an internalcombustion engine, in which the crankcase emissions materials,containing at least one of partially and completely unburned hydrocarbonmaterials, oil, particulate materials and gaseous combustion byproducts,are drawn from the crankcase of the engine and directed to an air intakeportion of the engine for recirculation through and further combustionin the engine, the apparatus for treatment of crankcase emissionsmaterials in a positive crankcase ventilation system comprising: afiltering apparatus, for containing a liquid filter medium, thefiltering apparatus being operably configured to receive therethroughcrankcase emissions materials conducted substantially directly from thecrankcase of an internal combustion engine, for substantially separatingremoving said at least one of said partially and completely unburnedhydrocarbon materials, oil, particulate materials and gaseous combustionbyproducts from crankcase emissions materials; the filtering apparatusincluding a housing, having an inlet and an outlet; the inlet of thehousing being operably connected, at least indirectly, to a positivecrankcase ventilation outlet of an internal combustion engine, theoutlet of the filter medium reservoir being operably connected, at leastindirectly, to a positive crankcase ventilation vacuum port of aninternal combustion engine; at least one baffle member, operablydisposed within the housing, and configured for constrainingintroduction of the crankcase emissions materials, from the crankcase,into at least one treatment chamber defined by the at least one bafflemember and the housing, the housing further comprising a substantiallyhollow reservoir base operably configured for receiving and containing aliquid filter medium; and a reservoir top, including an inner treatmentchamber, and a surrounding outer treatment chamber.
 28. The apparatusaccording to claim 27, wherein the reservoir base is an open-toppedtreatment chamber, defined by a first tubular side wall having an upperrim, and a bottom wall; the inner treatment chamber of the reservoir topis an open-bottomed treatment chamber, defined by a second tubular sidewall having a lower rim; and the outer treatment chamber is defined by athird tubular side wall surrounding at least a portion of thesubstantially tubular wall of the inner treatment chamber, the wall ofthe outer treatment chamber having a lower rim.
 29. The apparatusaccording to claim 28, wherein the inlet is disposed in the reservoirtop, in fluid communication with the outer treatment chamber thereof,and the outlet is also disposed in the reservoir top, in fluidcommunication with the inner treatment chamber thereof.
 30. Theapparatus according to claim 29, wherein the at least one baffle membercomprises: an open-topped tubular member, operably configured, uponpositioning within the housing, for defining an inner treatment chamberof the reservoir base, that is in fluid communication with the innertreatment chamber of the reservoir top, and an outer treatment chamber,disposed between a tubular side wall of the tubular member and the firsttubular side wall of the reservoir base; the outer treatment chamberbeing in fluid communication with the outer treatment chamber of thereservoir top; at least one aperture extending through the tubular sidewall of the tubular member; the tubular member further being operablyconfigured for cooperation with the reservoir top, so that upon assemblyof the housing and at least one baffle member, direct fluidcommunication between the outer treatment chamber of the reservoir topand the inner treatment chamber of the reservoir top are substantiallyprecluded, so that fluid passing through the housing is constrained topass, in succession, into the inlet, through the outer treatment chamberof the reservoir top, to the outer treatment chamber of the reservoirbase, then to the inner treatment chamber of the reservoir base, then tothe inner treatment chamber of the reservoir top and through the outlet,thus passing through liquid filter medium that may be disposed withinthe reservoir base.
 31. The apparatus according to claim 30, wherein thetubular member further comprises: a first tubular portion, having anupper rim region and operably configured to be received within thereservoir base, and having a width substantially equal to the width ofthe lower rim of the wall of the inner treatment chamber of thereservoir top; at least one abutment surface, disposed proximate anupper rim region of the first tubular portion, for engaging the lowerrim of the wall of the inner treatment chamber of the reservoir top,when the tubular member is placed in the reservoir base and thereservoir base and reservoir top are assembled, so that the reservoirtop forces a lower rim of the first tubular portion of the tubularmember against the bottom wall of the reservoir base, to createsubstantially fluid tight seals between the lower rim of the innertreatment chamber of the reservoir top and the at least one abutmentsurface, and between the lower rim of the first tubular portion of thetubular member and the bottom wall of the reservoir base.
 32. Theapparatus according to claim 31, wherein the at least one aperture inthe tubular member is disposed proximate the upper rim region of thefirst tubular portion.
 33. The apparatus according to claim 31, whereinthe at least one aperture in the tubular member is disposed proximatethe lower rim of the first tubular portion.
 34. The apparatus accordingto claim 31, wherein the at least one aperture in the tubular membercomprises at least two apertures in the first tubular portion, at leasta first of the at least two apertures being disposed proximate the upperrim region of the first tubular portion, and at least a second of the atleast two apertures being disposed proximate the lower rim of the firsttubular region.
 35. The apparatus according to claim 31, furthercomprising means for inhibiting suction of liquid filter medium into theintake system of an internal combustion engine to which the system isconnected.
 36. The apparatus according to claim 35, wherein the upperrim region of the first tubular portion of the tubular member defines apredetermined height corresponding to a maximum amount of liquid filtermedium to be placed in the housing, the means for inhibiting suction offilter medium further comprising: a second tubular portion of thetubular member, having a width predominantly less than the width of theinner treatment chamber of the reservoir top; the second tubular portionof the tubular member emanating from and extending above the firsttubular portion of the tubular member, to an elevation higher than theoutlet of the inner treatment chamber of the reservoir top, when thehousing and at least one baffle member are assembled, so that thehousing may be tipped up to a predetermined angle, without having filtermedium reach the outlet of the housing.
 37. The apparatus according toclaim 36, further comprising means for returning liquid filter medium,that may be carried out of the inner treatment chamber of the reservoirbase and subsequently condense in the inner treatment chamber of thereservoir top, to the inner treatment chamber of the reservoir base. 38.The apparatus according to claim 37, wherein the means for returningfilter medium comprises: a top wall of the inner treatment chamber ofthe reservoir top, contoured to have a low point disposed above the opentop of the tubular member, so that filter medium that may condense on aninner surface of the top wall of the inner treatment chamber will beprompted to collect and drip off from the low point, back into the innertreatment chamber of the reservoir base.
 39. The apparatus according toclaim 38, wherein the means for returning filter medium comprises: anaperture in the second tubular portion of the tubular member, forpermitting condensed liquid filtering material that may become trappedbetween the second tubular portion of the tubular member and the wall ofthe inner treatment chamber of the reservoir top, to flow back into theinner treatment chamber of the reservoir base.
 40. The apparatusaccording to claim 31, wherein the cross-sections of each of the firsttubular side wall, the second tubular side wall, the third tubular sidewall and the tubular side wall of the tubular member have a commonconfiguration selected from the group of shapes consisting of:cylindrical, rectangular, triangular.
 41. The apparatus according toclaim 27, wherein the housing comprises: a substantially hollowreservoir operably configured for receiving and containing a liquidfilter medium.
 42. The apparatus according to claim 41, wherein the atleast one baffle member comprises: an open-topped tubular member,disposed within the housing, and defining a generally cylindrical innertreatment chamber and a generally annular outer treatment chamber. 43.The apparatus according to claim 42, further comprising: a fluidseparator member, operably disposed between the housing and the at leastone baffle member, for partitioning the generally annular outer memberinto a first annular outer member in direct fluid communication with theinlet to the housing, and a second annular outer member in direct fluidcommunication with the outlet from the housing.
 44. The apparatusaccording to claim 43, further comprising at least one circumferentiallyextending baffle wall emanating upwardly from the at least one bafflemember toward a top wall of the housing.
 45. The apparatus according toclaim 43, further comprising at least one circumferentially extendingbaffle wall emanating downwardly from a top wall of the housing towardthe at least one baffle member.